Packaging system

ABSTRACT

A packaging system including an overlay having opposing upper and lower surfaces, the lower surface disposable on an upper surface of a pallet and the upper surface having a plurality of channels formed therein, and a plurality of sheets of at least one of card stock and paper disposed on the upper surface of the disposable overlay

BACKGROUND

[0001] The present application is directed to a packaging system.

[0002] It is known in the art to provide a pallet such as is shown in U.S. Pat. Nos. 5,606,921 and 6,209,464. These pallets are used for transporting materials, such as cardstock or paper, to the machinery, and have channels formed therein to receive elements of the machinery that is used to lift the cardstock or paper off of the pallet.

BRIEF DESCRIPTION OF THE DRAWINGS

[0003]FIG. 1 is a schematic diagram of a packaging system and associated pallet;

[0004]FIG. 2 is a perspective view of a first example of an overlay for use with the packaging system of FIG. 1;

[0005]FIG. 3 is a fragmentary, cross-sectional view of a first example of a construction for the overlay of FIG. 2;

[0006]FIG. 4 is a fragmentary, cross-sectional view of a second example of a construction for the overlay of FIG. 2;

[0007]FIG. 5 is a fragmentary, cross-sectional view of a third example of a construction for the overlay of FIG. 2; and

[0008]FIG. 6 is a perspective view of a second example of an overlay for use with the packaging system of FIG. 1.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS

[0009] Although the following text sets forth a detailed description of numerous different embodiments of the invention, it should be understood that the legal scope of the invention is defined by the words of the claims set forth at the end of this patent. The detailed description is to be construed as exemplary only and does not describe every possible embodiment of the invention since describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims defining the invention.

[0010] It should also be understood that, unless a term is expressly defined in this patent using the sentence “As used herein, the term ‘______’ is hereby defined to mean . . . ” or a similar sentence, there is no intent to limit the meaning of that term, either expressly or by implication, beyond its plain or ordinary meaning, and such term should not be interpreted to be limited in scope based on any statement made in any section of this patent (other than the language of the claims). To the extent that any term recited in the claims at the end of this patent is referred to in this patent in a manner consistent with a single meaning, that is done for sake of clarity only so as to not confuse the reader, and it is not intended that such claim term by limited, by implication or otherwise, to that single meaning. Finally, unless a claim element is defined by reciting the word “means” and a function without the recital of any structure, it is not intended that the scope of any claim element be interpreted based on the application of 35 U.S.C. § 112, sixth paragraph.

[0011]FIG. 1 illustrates an exemplary packaging system 20 disposed on a pallet 22. The packaging system 20 may include an overlay 24 and a load 26, for example a plurality of sheets of paper, card stock or the like.

[0012] The pallet 22 may have frame 28 having opposing surfaces 30, 32. As shown in the orientation in FIG. 1, the surface 30 may be referred to as the upper surface, while the surface 32 may be referred to as the lower surface. However, it will be recognized that pallet 22 may be inverted, such that the surface 30 may then be referred to as the upper surface, and the surface 32 may be referred to as the bottom surface. The pallet 22 may also have opposing sides 34, 36, 38, 40 in which are formed sets of slots 42, 44, the slots 42 formed in the sides 34, 38 and the slots 44 formed in the sides 36, 40. These slots 42, 44 are used to accept the rails of a forklift or pallet lifter, for example, so that the pallet 22 may be moved from place to place. Alternatively, the slots may be formed in the surfaces 30, 32 for accepting the rails of a forklift or pallet lifter.

[0013] The pallet 22 may be formed by attaching a plurality of wooden boards together with fasteners, like nails or screws, for example. Alternatively, the pallet 22 may be formed by molding the pallet 22 as a single piece. One of ordinary skill in the art will recognize other methods of forming the pallet 22 that may be used as well.

[0014] The overlay 24 is shown in greater detail in FIGS. 2-6. FIGS. 2 and 6 show different examples of the overlay 24, wherein similar elements have been numbered similarly. The similar elements of the overlay 24 shown in FIG. 6 are designated with a prime.

[0015] Referring first to the example of the overlay 24 in FIG. 2, the overlay 24 may have opposing surfaces 46, 48. As shown in FIG. 2, the surface 46 may be referred to as the upper surface, and the surface 48 may be referred to as the lower surface. The lower surface 48 of the overlay 24 may be disposed on the upper surface 30 of the pallet 22.

[0016] A plurality of channels 50 may be formed in the upper surface 48 of the overlay 24. While the channels 50 have been shown extending from one side 52 over the overlay 24 to another side 54, the channels need not extend entirely from the side 52 to the side 54. Furthermore, while three channels 50 are shown in FIG. 2, the overlay 24 may be formed with any number of channels 50. The number of channels 50 may be selected to match a machine (not shown) that may be used to move the load 26 disposed on the upper surface 46 of the overlay 24, for example.

[0017] FIGS. 3-5 show examples of the construction of the overlay 24 of FIG. 2.

[0018] As shown in FIG. 3, the overlay 24 may include a plurality or stack of sheets 58, each of which may have opposing sides 60, 62. The sheets may be attached to each other by affixing the sides 60 to the sides 62 with glue or adhesive, for example. The side 60 of the first sheet 58 (which may function as a base for the stack) defines the lower surface 48 of the overlay 24, while the side 62 of the last sheet 58 defines, at least in part, the upper surface 46.

[0019] To form the channels 50 using this construction, the sheets 58 may be all of the same size initially, and then sections of the sheets may be cut and removed from the laminated stack of sheets 58. To facilitate the removal of the sections of the sheets 58, glue or adhesive may not be applied to those sections of the surface 62 of the first sheet 58 that underlie the sections of the remaining sheets that will be removed later in the process. Alternatively, the sheets 58 overlying the first sheet 58 may be sized such that when affixed to the first sheet 58, the channels are formed in between the assembled sheets 58.

[0020] As shown in FIG. 4, the overlay 24 may be formed of a single sheet 64 that has been molded into the structure shown in FIG. 2. As shown, the sheet 64 may have a serpentine cross-section. That is, the sheet 64 may define walls 66, 68, 70 having opposing surfaces 72, 74, 76, 78, as well as walls 80, 82 with surfaces 84, 86, 88, 90. The walls 66, 68, 80, and in particular the surfaces 72, 74, 84, define the channels 50, while the walls 68, 70, 82, and in particular the surfaces 76, 78, 90, define in part a plurality of interior spaces 92, one of which is shown in FIG. 4, along with end walls 94 shown in FIG. 2. Also, the surfaces 86 of the walls 80 may define the lower side 48 of the overlay 24, while the surfaces 88 of the walls 82 may define the upper side 46 of the overlay 24.

[0021] A still further example of the overlay 24 is shown in FIG. 5. The overlay 24 may include a single sheet 96 having a first surface 98 and a second surface 100. A plurality of truss-like structures 102, each of which may be formed of a plurality of joined hexagons and has a first surface 104 and a second surface 106, may be disposed on the sheet 96 with the first surface 104 disposed on the second surface 100 of the sheet 96. A further sheet (not shown) may be disposed on the second surface 106 of the truss-like structures 102. The truss-like structures 102 may be spaced apart to define the channels 50.

[0022] A second exemplary overlay 24′ is shown in FIG. 6. The overlay 24′ like the overlay 24 shown in FIG. 4, may be formed of a single sheet 108 that has been molded into a structure having a serpentine cross-section. That is, the sheet 108 may define walls 110, 112 having opposing surfaces 116, 118, 120, 122 as well as walls 124, 126 with surfaces 128, 130, 132, 134. It will be recognized that the walls 110, 112, 124, and in particular the surfaces 116, 118, 128, define a first plurality of channels 50′, while the walls 110, 112, 126, and in particular the surfaces 120, 122, 134, define a second plurality of channels 50″. This exemplary overlay 24′ may thus be used either with the surfaces 130 of the walls 124 defining the lower surface 48′ and the surfaces 132 defining the upper surface 46′, or the surfaces 130 may define the upper surface 46′ and the surfaces 132 may define the lower surface 48′.

[0023] As shown, the walls 110, 112 are inclined relative to each other, so as to define a wave having a trapezoidal-type shape. Alternatively, the sheet 108 may be formed to define a wave having a square-type shape (not shown), such that the walls 110, 112 are parallel to each other, or the sheet 108 may be formed to define a sinusoidal-type shape (not shown). As a further alternative, a truss arrangement (not shown) may be disposed in one of the plurality of channels 50′, 50″ to strengthen the overlay 24′.

[0024] The exemplary overlays 24, 24′ discussed above may be made of a variety of materials. The exact type of material, as well as the construction of the overlay 24, 24′, selected may depend on a variety of factors, including, for example, the size and uniformity of the load 26 to be disposed on the overlay 24, 24′, the environmental conditions to which the overlay 24, 24′ is to be exposed (e.g. temperature, moisture, etc.), and the type of pallet 22 with which the overlay 24, 24′ is to be used. Moreover, where the overlays 24, 24′ may be made of a material such as cardboard, corrugated cardboard, chipboard or pulpboard, the overlay 24, 24′ may be disposable; that is, after the load 26 is unloaded from the overlay 24, 24′, the overlay 24, 24′ may not be reused. However, the overlay may be made of a material that is reusable as well. Additionally, the truss-like structure 102 may be formed of a hexacomb material.

[0025] The packaging system 20 including the overlay 24, 24′ and the load 26 may be assembled together to be placed as a single unit on the pallet 22. For example, the load 26 may be disposed on the upper surface 48, 48′ of the overlay 24, 24′, and the assembled packaging system 20 may be wrapped in a cellophane-type wrap, for example. After this fashion, the packaging system 20 may be used with a variety of pallets 22. 

What is claimed is:
 1. A packaging system comprising: an overlay having opposing upper and lower surfaces, the lower surface disposable on an upper surface of a pallet and the upper surface having a plurality of channels formed therein; and a plurality of sheets of at least one of card stock and paper disposed on the upper surface of the disposable overlay.
 2. The packaging system of claim 1, wherein the overlay comprises one of cardboard, corrugated cardboard, chipboard, and pulpboard.
 3. The packaging system of claim 1, wherein the overlay comprises stack of sheets, each of the sheets comprising a first surface and a second surface with the first and second surfaces of the sheets affixed to one another to define a laminated stack of sheets.
 4. The packaging system of claim 3, wherein the overlay comprises: a base comprising a first sheet having a lower surface defining the lower surface of the overlay and an upper surface; and a plurality of sheets disposed on the upper surface of the base, each of the sheets comprising a first surface and a second surface with the first and second surfaces of the sheets affixed to one another to define a laminated stack of sheets and the plurality of channels defined therein.
 5. The packaging system of claim 1, wherein the overlay comprises a single sheet having a serpentine shape with a first surface defining a first plurality of channels and a second surface defining a second plurality of channels.
 6. The packaging system of claim 5, wherein the overlay comprises a trapezoidal-type wave shape.
 7. A system comprising: a pallet being shaped to accept the rails of a forklift and having opposing upper and lower surfaces; an overlay having opposing upper and lower surfaces, the disposable overlay having its lower surface disposed on the upper surface of the pallet and having a plurality of channels formed in the upper surface; and a plurality of sheets of at least one of card stock and paper disposed on the upper surface of the disposable overlay.
 8. The system of claim 7, wherein the overlay comprises one of cardboard, corrugated cardboard, chipboard, and pulpboard.
 9. The system of claim 7, wherein the overlay comprises stack of sheets, each of the sheets comprising a first surface and a second surface with the first and second surfaces of the sheets affixed to one another to define a laminated stack of sheets.
 10. The system of claim 9, wherein the overlay comprises: a base comprising a first sheet having a lower surface defining the lower surface of the overlay and an upper surface; and a plurality of sheets disposed on the upper surface of the base, each of the sheets comprising a first surface and a second surface with the first and second surfaces of the sheets affixed to one another to define a laminated stack of sheets and the plurality of channels defined therein.
 11. The system of claim 10, wherein the overlay comprises a single sheet having a serpentine shape with a first surface defining a first plurality of channels and a second surface defining a second plurality of channels.
 12. The system of claim 11, wherein the overlay comprises a trapezoidal-type wave shape. 